13.0 How to Replace a Key
Tools Required
‘Pozi Drive’ Screwdriver. Bit size PZ1 & referred to as cross head and a 7mm socket or
spanner for M4 nuts.
General Notes
Replacing a Key should take less than 20 minutes if you have carried out this operation
before. This time can be reduced if you use a Pozi (PZ1) bit with a battery operated drill to
remove & fix screws that hold the Bottom Panels. But only use a battery operated drill if
you are proficient with using one. If using a battery powered drill take special care by
engaging the bit properly & starting slowly with some end pressure to stop the bit slipping
but also not too hard to damage the threads. Make sure not to over tighten the screws that
hold the bottom cover and this means carrying out the final tightening of the screws by
hand if necessary. If using a battery powered drill you will have to stop before the screws
‘bottom out’ i.e. slowing down well before then. You cannot rely on any torque limiter that
comes with the drill. Hand tightening means just ‘nipping up’ the screws.
Description
1/ Find a suitable area to carry out the task. You can set up on a fine carpet if the carpet is
clean (so as not to scratch the wooden bars when resting on the carpet). If the floor does
not have a suitable carpet then use cloth 1600cm x 30cm (63” x 12”) minimum. Or you can
work on a table top with a table cloth.
2/ Now place the Xylosynth upside down onto the work area.
3/ Undo & remove, with the battery powered drill if you if you are able to, all cross head
screws securing the bottom panel. Make a note of the two (or 3 on a 4/5 octave) types of
screw so you can replace them correctly.
4/ Lift off bottom panel.
5/ Locate the key to be replaced. Gently pull off the white plastic housing after releasing
the springy plastic clip holding it in place. Now undo & remove the two nuts and crinkle
washers.
6/ To remove the Key you will need to do two operations at once. Get your hand under the
Key to be removed & work the Key out with your other hand. You may find this operation
easier if you are able to raise the instrument onto its front or back edge. You may need to
coax the connector housing through the hole. Take care not to pull the wires unduly.
7/ Re assembly is the opposite process but concern yourself with the points below as well
as the general notes at the top. When putting the new Key in be careful not to trap any
wires coming from the Key. Compare the wire loop with keys nearby as they should all be
the same. Also you can test this before putting the crinkle washers & nuts by moving the
wires into & out of the hole noticing that they are free to move. If not tease the wires so
that they become free. Now place and tighten up the nuts so the crinkle washers grip into
the circuit board and Aluminium but do not over tighten to completely flatten the crinkle
washers. Clean with tissue or cloth the two gold plated pins of the connector block to
remove any grease/oil that may have come from your fingers prior to pushing the the key
connector housing back onto the block. The housing only fits on one way. Place the
bottom cover back on and place and tighten a couple of screws in the Holes. Carefully
tighten the screws. Then turn the Xylosynth the correct way up and test the key to see if it
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